Build A Pair of Stereo Speakers

Step 4 Preparing The Sides: Part 1: Sawing

Next we need to cut out the large 0.75" particle board into the 4 different pieces listed in the previous step. Here are the pieces listed again:

1) The front piece: .......................... 10.0" X 16.0" ........... (2 total, 1 for each speaker)
2) The back piece: .......................... 8.50" X 14.5" ........... (2 total, 1 for each speaker)
3) The top and bottom pieces: ..... 10.0" X 9.25" ........... (4 total, 2 for each speaker)
4) The two side pieces: ................. 9.25" X 14.5" ........... (4 total, 2 for each speaker)

Using a table saw is probably the fastest and most ideal way to cut these pieces. But don't worry, if all you have is a hand held circular saw (like me) here is an alternate method to cut the wood. (if you have a hand saw or you don't have a saw, you might be screwed)

1) Find a long, straight piece of wood to use as a guide for the saw.
2) Draw out the line in which you need to cut along.
3) Find the distance from the saw blade to the edge of the actual saw. (only have to do this once)
4) Draw a line parallel to the first line, at the distance in step 3.
5) Clamp the wood guide, from step 1, along this line.
6) Cut the wood! The saw should glide along the wooden guide and make a perfectly straight cut.

Make sure all your measurements are very precise! Also don't forget to consider the thickness of the blade while cutting. The above method is tedious but can provide very accurate cuts.

It really doesn't matter how you cut the wood, as long as you end up with all 12 pieces at the end.

Next we need to cut the holes on which the speaker drivers will be mounted.